82 Maxim project

Hi. I'm returning to biking after a lengthy time of bikelessness, and have just purchased a 1982 Maxim 750 with <32,000 Km on the clock. It appears in fairly good shape, although has a few cosmetic issues, mostly arising from what appears to be a low-speed dump. It also desperately needs a paint job! I was fortunate to also purchase a mostly intact '83 Maxim 750 as a parts bike!

After replacing the voltage regulator/rectifier* from the parts bike, (or whatever that unit connected to the battery is!), the bike started and runs nicely. I intend to put it in storage for the winter, and use the off-season to restore, refurbish and customize it.

*The individual looking after the bike for the absent owner had helpfully attempted to charge the battery, and I believe had fried the device!

Some things that need to be addressed to make it road-worthy:

1. The brake reservoir sight 'glass' is badly deteriorated, and I'm concerned it may begin leaking. The reservoir itself has suffered road rash, so I'd like to replace it anyway. Are new or replacement parts available? EDIT: Just discovered the parts catalog! Yay!

2. The red warning light flashes while the engine is running. The charging system seems to be working, however, as all lights brighten when the revs increase. The previous owner installed a switch to turn off the warning light, but I'd much rather locate and repair the source of the problem. Any hints or tips on what I should look for? EDIT: Also found the electrical FAQs & related.

3. The stock exhaust system is pretty much intact, apart from a small scrape at the outer tip of the right-hand muffler. I plan to fit an after-market four-in-one performance header, and compatible air filter system, anyway. Any recommendations?

4. The kill switch appears non-functional. Could this be related to the previously mentioned flashing warning light? Any advice on how to fix this? EDIT: I'll read through the electrical FAQ and the switches posts some more

 

First and foremost: IMMEDIATELY check the rear brake for delamination, very common: http://xjbikes.com/Forums/viewtopic/t=15874.html

 

first, Welcome. Secondly, that is the bike I started with same paint and all. As previously noted, take hte 20 minutes and take the rear wheel off and check the brakes for Delamination, that 20 minutes very much could save you life. It is very common to happen on these.

 

No worries, friends. Since the machine is 28 years old, it'll pretty much require a complete and thorough renovation of all main components, including the braking systems.

I plan to refit the front hydraulics with stainless steel braided lines, and install new shoes on the rear drum.

After checking the price/availability of replacement parts, I've decided to repair most of the cosmetically damaged bits, if possible, rather than replace them. Have you any experience using HTS 2000, or similar products for repairing aluminum?
http://www.youtube.com/watch?v=N-cv3R4fWZc

I also plan to repair the shiny chrome bits, by having a professional fill the dents with a little brazing, which I'll grind and sand smooth, then have the bits re-chromed.

At some point I'll tackle the electrical system. Sigh...

With any luck it'll be road worthy by Spring.

:mrgreen: